Abstract: A door panel includes an outer panel having a generally planar body portion with inner and outer surfaces and a sidewall with a front edge. An inner panel includes a generally planar body portion with inner and outer surfaces and a sidewall with a front edge. A trim breaker interconnects the outer panel and the inner panel to form a vacuum cavity therebetween. The trim breaker includes first and second upright members interconnected by upper and lower cross members. The trim breaker further includes an inner channel and an outer channel spaced-apart from one another around the trim breaker. The outer channel is outwardly disposed around the inner channel. The front edge of the inner panel is received in the inner channel of the trim breaker, and the front edge of the outer panel is received in the outer channel of the trim breaker.

Abstract: A door panel comprising a body having front and rear door skins delimiting an interior for sandwiching filling material, an interlock provided with the body and configured to lock the front and rear skins and thereby prevent displacement of the front and rear skins along at least two transverse directions, and a reinforcement member provided between the front and rear door skins and extending transversely to the interlock for providing reinforcement to the body.

Abstract: A door includes a sandwich panel having first and second panels, and a honey comb core. The first and second panels have edge tabs foldable toward one another. There are inner frame sections disposed at edge sections of the sandwich panel and adjacent to the honey comb core and inwardly of the edge tabs. The edge tabs are folded toward one another over the inner frame sections.

Abstract: A door having acoustical sound isolation properties includes a rail or stile having surfaces with a first, second and third planar portions stepped inward from and parallel to each other. Blocking layers are disposed parallel to and below one of the door surfaces, with each blocking layer having an edge with an extending flange contacting and extending along the second planar portion of the third surface of the stile or rail. The flanges of the blocking layers restrict movement of the layers toward each other. Soft acoustical material is disposed in the door interior. Flexible transition layers extend along the stile or rail third planar portions and extend over the blocking layers and the soft acoustical material to provide support against denting forces to the door.

Abstract: The pane module comprises a pane element composed by glass sheets (31, 35) and provided with a border element (37, 38) by molding. The border element is adhered to the pane element during the molding process and at least partially encases the border of at least one sheet element.

Abstract: The present invention relates to a wood composite panel having a major planar portion, at least one panel portion, and an inwardly extending contoured portion surrounding the panel portion and interconnecting the major planar portion and the panel portion. The contoured portion defines an inter-relationship between a vector angle and a deep draw depth that achieve a satisfactory stretch factor. The present invention also relates to a door having the disclosed wood composite door facings, and methods of forming the facing and door.

Abstract: A door facing is provided. The door facing includes a body portion, and male and female alignment members protruding from a main surface area of the body portion. Also provided are door assemblies including the door facing and methods of making the door facing and the door assembly.

Abstract: A reverse molded, plant-on decorative panel component comprises a panel portion lying on a first plane, a skirt portion, and a contoured portion. The skirt portion has a first surface adapted to be exteriorly disposed and an opposite second surface adapted to be interiorly disposed in order to be adhesively secured to a planar surface. The contoured portion extends outwardly from and surrounds the panel portion and interconnects and is integral with the panel portion and the skirt portion. The skirt portion extends peripherally about the contoured portion.

Abstract: The invention relates to a method and device with which it is possible to arrange complicated shapes with considerable differences in height in wood fiber board, and in particular but not exclusively so called MDF (Medium Density Fiberboard). The deformation of the wood fiber board which can be achieved is known in the art as extrusion, wherein a considerable plastic deformation takes place accompanied by flow and stretch of the material.

Abstract: There is provided an embossed particleboard, which can be used, for example, as a siding. The particleboard comprises a monolayer embossed particleboard including wood particles having an average size of less than 4 mm, a resin, and optionally a sizing agent. There is also provided a method of manufacturing a wood-based product such as a siding. The method comprises embossing and pressing in a single step a monolayer mat comprising wood particles having an average size of less than 4 mm and a resin, so as to obtain an embossed monolayer particleboard siding.

Abstract: The outer rail retains two lateral screw webs of an intermediate rail to construct a base for wall plate covering. Two retention devices are disposed oppositely on respective inner sides of each retention web for retaining a respective screw web of the intermediate rail. Each retention device including an abutment part, which extends inwards from the inner side of the retention web such as to form an abutment surface for the respective screw web when the latter is positioned to be retained in the retention device, and extends from the abutment part into a locking part, which extends at an angle to the abutment part and at a distance from the respective retention web. Each locking part comprising a first resilient locking pin adapted to lock a first screw web configuration and a second, separate resilient locking pin adapted to lock a second screw web configuration, the first and second screw web configurations being pre-defined and different from each other.

Abstract: A hollow core door filters air flowing through the interior of the door between top and bottom rails of a perimeter frame and may absorb and decompose noxious or and undesirable materials used in the manufacture of door components and undesirable material in the air in the room or structure in which the door is located. The scrubbing action is accomplished by use of filtering material secured to one or both the top and bottom panels secured to the perimeter frame and to interior core elements. Air flowing within the door passes over the filtering or scrubbing material and the noxious material and gases are removed from the flowing air by the scrubbing material. Each of several embodiments of internal structural elements and materials allows for the flowing of the air to be cleansed and for undesirable materials or compounds to be absorbed and decomposed.

Abstract: A wall panel arrangement is adapted to be used in a wall panel system provided with at least one pair of spaced apart vertical frame members having inwardly facing sidewalls for retaining at least one existing panel therebetween. The wall panel arrangement includes an add-on wall panel assembly constructed with opposed face structure connected to opposed side structure, and adapted to cover at least a portion of the existing panel. Mounting structure is provided on the wall panel assembly, and is configured with flexible resilient retainers extending outwardly relative to the side structure, and adapted to frictionally engage the inwardly facing flat walls of the vertical frame members, and hold the wall panel assembly over the existing panel and between the vertical frame members.

Abstract: A molded door skin is provided that features a molded component having a stainable or stained exterior surface including molded grooves and molded tonal portions. The grooves are configured with variable depths and lengths with respect to one another and variably spaced with respect to one another to collectively simulate an appearance of a naturally appearing wood grain tick pattern. The tonal portions are configured to receive and retain sufficient stain to simulate an appearance of darkened naturally appearing wood grain background tone. Doors having the molded door skin or first and second molded door skins are also provided.

Abstract: A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about ?11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

Abstract: A door facing is provided. The door facing includes a body portion, and male and female alignment members protruding from a main surface area of the body portion. Also provided are door assemblies including the door facing and methods of making the door facing and the door assembly.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A wood-fiberglass hybrid panel door featuring natural wood veneer permanently bonded to at least one side of a fiberglass door. The panel and the stile/rail portions of the fiberglass door skin for bonding wood veneers can be either one-piece compression molded construction or can be separately compression molded pieces joined together by mechanical or chemical methods. The two pieces of door skins are used to make a fiberglass door first. Wood veneer is then bonded to at least one side of the said fiberglass door through the use of a vacuum press. Wood raised molding or flush sticking is applied around the veneered panel to cover the veneer edges on the panel and/or stiles/rails. Wood raised molding or flush sticking is fixed to the door by mechanical or chemical methods.

Abstract: A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.

Abstract: A molded door skin is provided that features a molded component having a stainable or stained exterior surface including molded grooves and molded tonal portions. The grooves are configured with variable depths and lengths with respect to one another and variably spaced with respect to one another to collectively simulate an appearance of a naturally appearing wood grain tick pattern. The tonal portions are configured to receive and retain sufficient stain to simulate an appearance of darkened naturally appearing wood grain background tone. Doors having the molded door skin or first and second molded door skins are also provided.

Abstract: A universal door skin blank comprises an exterior side and an interior side for securing to a frame member, first and second molded, spaced stiles, and a flat planar portion disposed between the stiles and lying on a plane spaced from the plane of the stiles. An interface portion is disposed between and contiguous with the stiles and the flat planar portion. The invention also relates to a door having at least one universal door skin blank, with at least two separately formed rails secured to the planar portion of the blank at opposite ends thereof.

Abstract: A door comprising first and second door skins secured to each other to form a cavity therebetween filled with expended foam. Each of the door skins has an opening therethrough for receiving a glass insert and a flange portion. Distal ends of the flange portions of the first and second door skins engage each other in an overlapping relationship by the expansion pressure of the expanded foam. The door further comprises a glazing rim member having a leg portion snap-locked between the flange portions of the first and second door skins. The method for assembling the door comprises the steps of filling the cavity between the door skins with foam material, then inserting the glass insert through the openings in the door skins and mounting the glazing rim member to the first door skin by snap-locking between the flange portions of the first and second door skins.

Abstract: The present invention relates to a door skin comprising an exterior surface having outer portions lying on a first plane, spaced grooves recessed from the plane of the outer portions, and tonal portions having a planar area and a plurality of spaced depressions recessed from the plane of said planar area. The present invention is also directed to a method of etching a plate, for use with a molded die set, for embossing a wood grain pattern in the door skin, and the etched plate formed therefrom.

Abstract: A three piece component (1, 51) comprising a main body (5, 50) having two stiles (3, 65) and at least one panel member (4, 56) intermediate and integrally formed with the two stiles (3, 65). At least one end of the main body (5, 50) defines an opening (6, 59) in the main body (5, 50) where the stiles (3, 65) extend beyond the panel member (4, 56) and at least one rail (2, 81) is formed for insertion into the opening (6, 59) at the end of the main body (5, 50).

Abstract: A wainscoting system for covering a portion of a wall, wherein the wainscoting system includes a lower rail secured to the wall, a chair rail assembly attached to the wall and spaced apart from the lower rail, a plurality of decorative panels extending between the lower rail and chair rail assembly, and a batten positioned adjacent decorative panels. The batten includes a compound tongue formed into a first side edge thereof and a compound tongue formed into an opposing second side edge thereof. Each decorative panel includes a compound tongue formed into a first side edge thereof and a compound groove formed into an opposing second side edge thereof. The compound tongue of each decorative panel corresponds and is engageable with the compound groove of the batten, and the compound groove of each decorative panel corresponds and is engageable with the compound tongue of the batten.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: Embodiments of a carved solid face door having a window formed therein and methods of fabrication are disclosed herein. In some embodiments, a carved solid face door may include a solid base having a face and an opposing rear surface; and a window carved into the face and having an opening passing through the face to the opposing rear surface, wherein the window includes at least one of a frame, a trim, a molding, or mullions carved into the face that emulate the appearance of multiple-piece construction.

Abstract: A large opening rolling door of the articulating type has multiple horizontally and vertically distributed insulative glass panes supported by a plurality of vertically disposed and horizontally disposed heat transmitting metal frame members arranged in vertical and horizontal regions respectively between adjacent glass panes. The horizontal frame members have opposed and closed or open and recessed edge volumes in the closed condition of the door; preformed, self-supporting, self-camming and self-compressing and cooperating male and female insulator bands that interfit with the open and recessed edge volumes, or insulation filled beams, in the closed condition of the door define insulation in the horizontal regions. Vertical frame members define a substantially enclosed volume in which a preformed, self-supporting insulator band is inserted into the volume to insulate the vertical regions and thus substantially the entire door against heat transmission therethrough.

Abstract: A reverse molded, plant-on decorative panel component comprises a panel portion lying on a first plane, a skirt portion, and a contoured portion. The skirt portion has a first surface adapted to be exteriorly disposed and an opposite second surface adapted to be interiorly disposed in order to be adhesively secured to a planar surface. The contoured portion extends outwardly from and surrounds the panel portion and interconnects and is integral with the panel portion and the skirt portion. The skirt portion extends peripherally about the contoured portion.

Abstract: The present invention is a door with a modular frame which can be installed and removed easily. In several embodiments the door is constructed to fit in a standard interior doorway without modifications to the existing door frame. In several embodiments the opening is constructed in the upper half of the door. In several embodiments the screen is constructed in a modular frame for easy replacement of the screen if damaged or if other material such a glass or acrylic glass is desired in the opening. In several embodiments the modular frame can be replaced without tools. In several embodiments the modular frame could hold a number a different inserts. In several embodiments the door has a regular door panel on one side and an opening with a modular frame on the other side. In several embodiments the door has a self supporting screen.

Abstract: A composite product includes gypsum in an amount of 70 to 90% by weight, fibers in an amount of 1.5 to 26% by weight substantially homogeneously distributed through the composite, and a rheology-modifying agent in an amount of 0.5 to 6% by weight. The composite is caused or allowed to cure to form a cured composite. The cured composite is a fire resistant component used in a fire-rated door core, a fire-rated door or a fire-rated building panel. The fire resistant component may include a building panel, a door panel, a door core, a door rail, a door stile, a door lock block, a door border, or a door insert.

Abstract: A method of assembling a powder coated wall frame supporting a wooden panel therein, by: (1) powder coating various metal members; (2) connecting top and side metal members together to form a frame having an open bottom; (3) inserting a wooden panel into the open bottom of the frame; and then (4) connecting a bottom metal member onto the side members, thereby sealing the wooden panel within the metal frame structure.

Abstract: Disclosed is a raised profile panel having various patterns for a door, which allows a user to repair a profile of the door or change a design of the door according to the demand of the user without exchanging the door with a new one when the profile formed on a surface of the door for decoration is damaged or the user wants to change the design of the door. The raised profile panel includes a profile section manufactured separately from the door and having a bonding surface forming an inner wall of the profile section and an exposed surface forming an outer wall of the profile section; and an adhesive layer provided on the bonding surface of the profile section to bond the bonding surface of the profile section with the surface of the door.

Abstract: A method comprises a) attaching a first skin to a first surface of an open cell foam to form a precursor for a door, window or panel; and b) attaching a second skin to the precursor in a separate step from step a). A precursor for a door, window, or panel, comprises a skin attached to one face of an open cell foam, but not to an opposing face of the open cell foam.

Abstract: The present invention concerns a method of forming a multi-ply core component. A mold press is provided having an upper die and a lower die defining a mold cavity. At least one of the upper die and the lower die has a plurality of protrusions. A first wood composite board and a second wood composite board are disposed within the mold cavity. The first and second boards are fused proximate the plurality of protrusions by compressing the boards in the mold cavity through application of heat and pressure.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A wood-fiberglass hybrid panel door featuring natural wood veneer permanently bonded to at least one side of a fiberglass door. The panel and the stile/rail portions of the fiberglass door skin for bonding wood veneers can be either one-piece compression molded construction or can be separately compression molded pieces joined together by mechanical or chemical methods. The two pieces of door skins are used to make a fiberglass door first. Wood veneer is then bonded to at least one side of the said fiberglass door through the use of a vacuum press. Wood raised molding or flush sticking is applied around the veneered panel to cover the veneer edges on the panel and/or stiles/rails. Wood raised molding or flush sticking is fixed to the door by mechanical or chemical methods.

Abstract: A door facing blank is provided that includes a central portion, first and second side portions adjacent to and integral with opposite sides of the central portion, opposite interior and exterior major surfaces, and a design element including a molded portion and an embossed portion. The side portions include stile-receiving areas that are substantially planar. The molded portion is molded in the central portion to establish a first groove portion in the exterior surface region of the central portion and a protrusion on the interior surface region of the central portion. The embossed portion is embossed in the first side portion to establish a second groove portion in the exterior surface region of the first side portion but no protrusion on the interior surface region of the first side portion. The first and second groove portions establish a continuous groove in the exterior major surface.

Abstract: The present invention relates to a wood composite panel having a major planar portion, at least one panel portion, and an inwardly extending contoured portion surrounding the panel portion and interconnecting the major planar portion and the panel portion. The contoured portion defines an inter-relationship between a vector angle and a deep draw depth that achieve a satisfactory stretch factor. The present invention also relates to a door having the disclosed wood composite door facings, and methods of forming the facing and door.

Abstract: A door, method of making a door, and stack of doors includes providing a door having front and back skins that have differing, but complementary profiles, one for the front side of the door and one for the back side of the door where each allows and fits onto the other, while still providing direct contact in the stile and rail zones of the door permitting conventional door layup practices.

Abstract: The preferred embodiment utilizes a wood insert panel with notches at the top and center and at the bottom and center and a wood frame with protrusions that correspond with the notches and that are located in the center of the rails of the wood frame. The interlocking of the notches and protrusions permit for expansion of the wood insert panel within the grooves in the stiles of the wood frame while still centering and supporting the wood insert panel within the wood frame.

Abstract: A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about ?11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

Abstract: A door panel includes a frame, a laminate core, a plurality of thermally-insulative connectors, and an exterior skin. The frame defines a portion of an outer periphery of the panel and has an inner section and an outer section positioned, respectively, adjacent inner and outer portions of the panel. The laminate core is positioned between the inner section and the outer section of the frame. The plurality of thermally-insulative connectors connect the inner section and the outer section to the core. The exterior skin covers the frame. The core is a thermal barrier between the inner section and the outer section. The inner section and the outer section are formed from a thermally-insulative material. The core includes an inner layer formed from a thermally conductive material, and two outer layers formed from steel. The thermally-insulative connectors include a thermally-insulative jacket and a fastener positioned within the jacket.

Abstract: The present relates to a sidelite assembly having first and second panels and a window. Each of the panels has an inner edge extending outwardly from a major planar portion and surrounding an opening. The inner edge includes a first portion having a ridge extending outwardly from a distal end thereof and a second portion having a channel extending inwardly from the distal end. An outer edge extends outwardly from the major planar portion and adjacent a periphery thereof, and includes a first portion having a ridge extending outwardly from a distal end thereof and a second portion having a channel extending inwardly from the distal end. The ridges of the first panel are aligned with and received in the channels of the second panel. The window is disposed within the opening.

Abstract: A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.

Abstract: A window assembly for a wall opening can have a center bar removably engaged to a window assembly frame; the center bar having at least one deep channel to receive an edge of at least a first window pane within a portion of a channel depth on a first side and having at least a second channel on a second side of the center bar to receive an edge of a second window pane; and the center bar lowerable over the first window pane edge when disconnected to the frame to a depth within the deep channel to allow the second window pane to be disengaged from the second channel.

Abstract: The present invention is directed to a method of printing an image on an object, such as a door facing or a door. An object having an exterior surface is provided. A first image component is printed on the exterior surface. A first transparent coat is applied on the exterior surface so as to cover the first image component. A second image component is printed on the first transparent coat. Optionally, a second transparent coat is applied to the first transparent coat and second image component so as to cover the first and second image components. The resulting object, such as a door, having the printed image thereon is also disclosed.

Abstract: A door assembly with installed glass panel, or insulated glass panel, security glass panel, or a decorative leaded glass panel, void of holes in the door or in glass panel, wherein the door assembly has a dual support connector with connector body, connector hole extending through the connector body, a glass flange integral with the connector body for overlaying an edge portion of the glass panel; an structural panel flange integral with the connector body, extending at a right angle to the connector hole away from the connector body parallel to while opposite the glass panel flange for overlaying an edge portion of the structural panel while in a plane apart from a plane of the glass flange.

Abstract: A custom shutter includes a central body portion and first and second end caps. The central body portion includes two stiles and a central portion all of which are formed integrally as one piece. The top and bottom end caps include first and second legs and a central connecting body portion. The legs are designed to be inserted within the hollow interior of the stiles with the top edges of the stiles resting against the stepped portions of said end cap and wherein an inner surface of said end cap covers any exposed edge of the central portion of the shutter body.

Abstract: A frame (1) for receiving and holding a removable board (2) for use in the manufacture of edible products such as bread and the like. The frame (1) comprises a plurality of side walls (100, 101, 102, 103) and reinforcing cross-members (104, 105, 106) so that a board (2) which is adapted to be retained within the frame (1) is protected from damage and wear during transportation along mechanized conveyors in the bread making process. The board (2) is provided with a lip which extends around its perimeter and projects laterally beyond the side walls of the frame to enable removal of the board from the frame. The board (2) further comprises a textured upper surface which helps to prevent dough from sticking and facilitates the eventual removal of the dough from the board.